Woodcraft_Magazine_-_October-November_2019

Rout the slot as shown. Then drill counterbores for the
pivot bar lock 3⅜" from the edge as per the drawing
on page 53. Slide the bar in the slot to ensure that
its top sits above the counterbores’ depth. Drill ¼"
holes through the counterbore centers. Round the
sled corners, then ease the edges with sandpaper.
Next, cut a 12" length from the aluminum bar, and drill
two ⅛" holes for the pivot pins, locating them ½" and 5½"
from one end. (You’ll use the endmost pivot point for small
discs, and the other for larger discs.) Now, drill and tap

holes into the bar’s edges. Then adjust the plastic screws in

the offcut section of the bar so that the bar slides in your

bandsaw’s table slot freely but without slop. Measure for

the stop block as shown. From ¾ × 3½" stock, crosscut one

piece to your stop block measurement plus 1⁄16". Also cut

a 4"-long piece for the anti-tilt block. Install the threaded

insert in the stop block at the center of your fence rail, and

mount the stop assembly. To finish up, sand the top surface

smooth, then shellac and wax it to minimize friction. Then

insert the 3" bolt through the star knob and stop block.

Rout the slot. Attach a fence parallel to the pivot slot layout, and on the left
side of the router. Position a stop so the slot ends about^1 ⁄ 2 " from the blade’s
path and rout the slot in several light passes, pushing the router forward.

Mount the bar. Place the sled on your saw’s table to
mark the table slot location. At the bench, mount the
bar squarely and flush with the outfeed edge.

Measure for the stop. For

round fence rails, set your

combination square to an even

measurement and rest it on

the table. Then use a smaller

square to gauge the distance

between the top of the table and

the lower edge of the fence rail.

Mount the stop. Set the

stop assembly on the sled

bottom about^1 ⁄ 8 " in from

the infeed end, and mark

and drill the pilot holes.

Counterbore the anti-tilt

block so that the screws

reach^5 ⁄ 8 " into the sled.

Tap the bar. Cross-drill through the bar with a #29 bit at the

two pivot pin locations, then use a #8-32 tap to cut threads.

Install brass-tipped setscrews to anchor the pivot pins.

Rout the slot, drill the holes, and mount the hardware

Stop

Fence

Travel-

adjustment

set screw

Table slot location

(^1) ⁄ 8 " pivot
pin hole
Outfeed edge
Blade cut line
Kreg bar

54